Technology: 5.4 - Advanced Structures and Materials

5.Technology

- 5.1 Engine and Powertrain
- 5.2 Hybrid, Electric and Alternatively Fuelled Vehicles
- 5.3 Advanced Software, Sensors, Electronics and Telematics
- 5.4 Advanced Structures and Materials
- 5.5 Design and Manufacturing Processes

Technology Targets

Technology target proposals appropriate to the FASMAT group were also considered in the workshop, and these are given in the following table. They should not been seen as definitive, but rather a view on suitable targets against which progress can be audited.

	0-5 years	5-10 years	10-20 years
Safety	Selection of joining systems to match material performance capabilities eg energy absorption, stiffness, strength etc	Design/production and validation of “smart” crash structures
Product configurability and flexibility	Component integration Easier separation of materials for recycling or re-use Effect of modular structures (and joining) on crash structures/NVH/stiffness Robust engineering solutions for rapid modular reconfiguration	Automotive industry relevant materials information database with all needs covered – one source Management of customer customisation and effect on design process/homologation and supply chain
Economics	Reduce cost of moulded composites Component performance beyond single vehicle life Development costs Re-processing of metal mixtures to give pure metals for re-use A higher, safer and more environmentally sound vehicle development.	Disassembly techniques Develop viable alternative to traditional paint finish for body panels
Environment	Establish standards for environmental friendliness Development of polymer separation techniques ELV compliant composite materials Reduce vehicle weight Attachment strategies for dismantling Wider understanding of materials in the industry Overcoming energy saving vs recycling perceptions Development of disbondable metal/composite interfaces National system for reuse of components. Low cost CFRP panels and structures.	New magnetic materials for hybrid/fuel cell powertrain Develop re-use mechanisms/methodologies Identify higher value markets for recovered materials National systems for material re-use and recycle.	Solve H2 fuel infrastructure issues to enable widespread uptake and use Hardwearing, low friction coatings to eliminate lubricants from powertrains
Manufacturing systems	Joining hybrid structures Surface quality thermoplastic composites Develop low cost composite manufacturing process Cost effective joining/dismantling of mixed material structures Cheap, environmentally friendly system to join steel, aluminium and magnesium without corrosion issues Awareness of and access to process cost models and LCA Establish central register of production routes to advise on potential facility sharing Single piece structure development costs.	Coatings which survive production Reduce time to manufacture for novel technologies Materials that do not require paint protection Convergence of business and technology research models Flat pack/modularity requires ability to make cheaply, structural, sealed joints post-paint process	Die-less forming

Research Priorities

Key materials & structures technologies for development are expected to include the following: -

Low investment, short cycle time, single sided access joining technologies for metallic and composite materials and having an inbuilt process monitor / validation mechanism e.g. riveting processes that set the rivet, applying suitable process monitoring and NDT strategies in cycle will enable automatic capture of the quality record for that specific assembly.

Predictive simulation of plastics, composites & foams under high strain rate conditions e.g. a prediction mechanism for foams would allow optimisation of energy absorption rates under impact conditions to protect the contents of the packaging or modify the response of the product or assembly that the foams forms a part of.

Low investment, environmentally acceptable corrosion resistant pre treatments for light metals (e.g. aluminium & magnesium) that would be suitable for low volume batch suppliers.

Medium & high volume techniques for the manufacture of low weight structural composite components and hybrid structural joining techniques to enable their use in predominantly metallic structures.

Robust manufacturing processes to enable the production of recyclable components & assemblies with structural, cosmetic and electrical / electronic functions integrated.

Low volume modular manufacturing techniques.

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Foresight Vehicle Secretariat, c/o SMMT Ltd, Forbes House, Halkin Street, London, SW1X 7DS. Email: info@foresightvehicle.org.uk